Audi Workshop Service and Repair Manuals

Removing and installing camshaft timing chain

Special tools and workshop equipment required

t	Locking pin -3242-

t	Special wrench -T40049-

t	2x Adjustment pin -T40060-

t	Adapter -T40061-

t	Adapter -T40062-

t  Diesel injection pump locking pin -3359- t  Nuts M12 (2x) t  Drill bit, Ø 3.3 mm Removing l  Gearbox removed.   Caution Avoid damage to valves and piston crowns. The crankshaft and camshafts must only be turned with the chain drive mechanism fully installed. –  Remove timing chain cover (bottom) → Chapter.

Caution Risk of damage to drive chain if thread of bolt exceeds specified length. t  Use bolts with a maximum thread length -a- of 22 mm to attach special wrench -T40049-. t  If no suitable bolts are available, position suitable washer(s) under bolt head so that remaining thread length does not exceed 22 mm.

–  Secure special wrench -T40049- onto rear of crankshaft.   Caution Irreparable damage can be caused if the camshaft timing chains slip. Turn crankshaft only in direction of engine rotation.   Note

t  The adjustment pin -T40060- has a flat -2- which makes it easier to insert when the locating bores in the camshaft and cylinder head are not exactly in line. t  The adjustment pin is inserted initially so that the side pin -1- is perpendicular to the imaginary line between the adjustment pin and the centre of the camshaft. t  To obtain the correct „TDC“ position, the side pin -1- must then be turned 90° -arrow- so it is in line with the imaginary line between the adjustment pin and the centre of the camshaft.

–  Rotate crankshaft to „TDC“: l  It should be possible to lock the camshafts with the adjustment pins -T40060-. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft on cylinder bank 1 (right-side).

l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft on cylinder bank 2 (left-side).

–  Unscrew plug -arrow- from sump (top section).

–  Screw locking pin -3242- into hole (20 Nm); if necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin.

–  Wrap insulating tape around tip and shaft of 3.3 mm Ø drill bit to avoid cuts. –  Press tensioning rail of camshaft timing chain tensioner (left-side) in direction of -arrow- and lock chain tensioner by inserting 3.3 mm Ø drill bit -item 1-. –  Remove guide pin -2- and detach tensioning rail.   Caution If a used timing chain rotates in the opposite direction when it is refitted, this can cause breakage. Mark running direction of timing chain with coloured arrows for re-installation.

–  Remove bolt -arrow- for chain slip preventer.

–  Remove adjustment pin -T40060- from both camshafts. –  Remove bolts -arrows-.

–  Remove bolts -arrows-. –  Remove camshaft sprockets and camshaft timing chain.

Installing l  Crankshaft -1- locked in „TDC“ position with locking pin -3242-. Tightening torques: l  → Chapter „Camshaft timing chain - exploded view“. l  → Chapter „Sump (top section) - exploded view“.   Note t  Renew the seal on the screw plug for the „TDC“ mark. t  Renew the bolts tightened with specified tightening angle.

–  Check that camshafts on both cylinder heads are positioned at „TDC“. l  It should be possible to lock the camshafts with the adjustment pins -T40060-. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft on cylinder bank 1 (right-side).

l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft on cylinder bank 2 (left-side). –  Remove adjustment pin -T40060- from both camshafts.

Caution Avoid damage to valves and piston crowns. The crankshaft must not be at „TDC“ at any cylinder when the camshafts are to be turned.   Note If the pins cannot be inserted in the camshafts, the camshafts can be turned slightly using adapter -T40061-. To do so, screw securing bolts for camshaft sprocket into camshaft.

–  Fit camshaft sprocket (left-side) with camshaft timing chain. l  The elongated holes in the camshaft chain sprocket must be aligned centrally over the tapped holes in the camshaft. –  First screw in two bolts -1- loosely for camshaft chain sprocket. l  It should just be possible to turn the sprocket on the camshaft without axial movement. –  Use adjustment pin -T40060- to lock camshaft (left-side). l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft.

–  Fit camshaft sprocket (right-side) with camshaft timing chain. l  The elongated holes in the camshaft chain sprocket must be aligned centrally over the tapped holes in the camshaft. –  First screw in two bolts -1- loosely for camshaft chain sprocket. l  It should just be possible to turn the sprocket on the camshaft without axial movement. –  Use adjustment pin -T40060- to lock camshaft (right-side). l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft.

–  Secure tensioning rail with guide pin -2-. –  Pull drill bit -1- out of locating hole, this releases the chain tensioner (right-side).

–  Loosen bolts -2-. –  Lock balance shaft -3- with diesel injection pump locking pin -3359-, as shown in illustration.   Note If necessary, remove bolts and bring balance shaft into position. –  Loosely screw in bolts -2-. l  It should just be possible to turn the sprocket -1- on the balance shaft without axial movement.

–  With the help of a second mechanic, apply a torque of 20 Nm to camshaft chain sprocket (right-side) in clockwise direction -arrow- using a torque wrench and adapter -T40062- and maintain this torque. –  Tighten bolts -1- and -2- for camshaft chain sprocket (right-side).

–  Tighten bolts -1- for camshaft chain sprocket (right-side); while doing so, second mechanic must keep maintaining torque.

–  Tighten bolts -2- at chain sprocket -1- for balance shaft -3-. –  Remove diesel injection pump locking pin -3359-, adapter -T40062- and adjustment pins -T40060-. –  Tighten remaining bolts for camshaft chain sprockets (both sides).

–  Remove locking pin -3242-.

Checking valve timing   Caution Irreparable damage can be caused if the camshaft timing chains slip. Turn crankshaft only in direction of engine rotation -arrow-. –  Turn crankshaft two rotations until it is again positioned just before „TDC“.

–  While turning in this direction, lock crankshaft -1- with locking pin -3242-. Tighten locking pin to 20 Nm.   Caution The crankshaft must be exactly in „TDC“ position to ensure accurate valve timing adjustment. If crankshaft has been turned past „TDC“ position, turn crankshaft two further rotations until it is again positioned just before „TDC“. Then turn further in the same direction and lock crankshaft with locking pin -3242-.

–  Check that camshafts on both cylinder heads are positioned at „TDC“. l  It should be possible to lock the camshafts with the adjustment pins -T40060-. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft on cylinder bank 1 (right-side).

l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft on cylinder bank 2 (left-side).

Adjusting valve timing –  If the pin cannot be inserted in one of the camshafts, loosen all bolts -arrows- of relevant camshaft chain sprocket approx. 1 turn.

–  Apply adapter -T40061- to the heads of the loosened bolts. –  Turn camshaft slightly backwards and forwards with adapter -T40061- until adjustment pin -T40060- can be inserted. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft. –  With adapter -T40061- and adjustment pin -T40060- still in position, tighten bolts on camshaft sprocket to approx. 5 Nm. –  Remove adjustment pin -T40060- and adapter -T40061-. –  Tighten bolts for camshaft chain sprocket to final torque. –  Repeat procedure on other cylinder bank if necessary. –  Remove locking pin -3242-. –  Check valve timing once again → Anchor. Remaining installation steps are carried out in reverse sequence; note the following: –  Install timing chain cover (bottom) → Chapter.